Coatings, materials and processes for lead and copper water service lines

ABSTRACT

Methods, processes, compositions and systems for preventing leaching effects from water pipes (such as lead, steel and copper) having an inner diameter of at least approximately 12 mm. 2-part thermoset resin coating is applied to the inner surfaces of the pipes where the curing agent can be a phenol free and plasticizer free adduct type. The coating can reduce heavy metals, such as lead, from leaching from installed pipes to less than approximately 10 μg/L (10 ppb). When cured, specific leachates, Bisphenol A and Epichlorohydrin from the coatings will be (less than)&lt;1 μg/L (1 ppb) with overall TOC levels measured at (less than)&lt;2.5 mg/L (2.5 ppm). Pipes can be returned to service within approximately 24 hours, and preferably within approximately 4 hours.

RELATED APPLICATIONS

This application is a Divisional Application of U.S. patent applicationSer. No. 14/011,260 filed Aug. 27, 2013, now allowed, which is aDivisional Application of U.S. patent application Ser. No. 13/566,377filed Aug. 3, 2012, now U.S. Pat. No. 8,524,320, which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.61/595,794 filed Feb. 7, 2012, and this invention is aContinuation-In-Part of U.S. patent application Ser. No. 13/210,659filed Aug. 16, 2011, now U.S. Pat. No. 8,887,660, which is a DivisionalApplication of U.S. patent application Ser. No. 12/947,012 filed Nov.16, 2010, now U.S. Pat. No. 8,354,140, which is a Divisional Applicationof U.S. patent application Ser. No. 12/378,670 filed Feb. 18, 2009, nowU.S. Pat. No. 8,206,783, which is a Divisional Application of U.S.patent application Ser. No. 11/246,825 filed Oct. 7, 2005, now U.S. Pat.No. 7,517,409, which is a Divisional Application of U.S. patentapplication Ser. No. 10/649,288 filed Aug. 27, 2003, now U.S. Pat. No.7,160,574, and which claims the benefit of priority to U.S. ProvisionalPatent Application Ser. No. 60/406,602, filed Aug. 28, 2002, and thisinvention is a Continuation-In-Part of U.S. patent application Ser. No.12/813,873 filed Jun. 11, 2010, now U.S. Pat. No. 8,343,579, to the sameassignee as the subject invention, which is a Divisional of U.S. patentapplication Ser. No. 12/723,115, filed Mar. 12, 2010, now U.S. Pat. No.8,033,242, which is a Divisional of U.S. patent application Ser. No.11/649,647 filed Jan. 4, 2007, now U.S. Pat. No. 7,858,149 which is aContinuation-In-Part of U.S. patent application Ser. No. 11/246,825filed Oct. 7, 2005, now issued as U.S. Pat. No. 7,517,409, which is aDivisional of U.S. patent application Ser. No. 10/649,288 filed Aug. 27,2003, now issued as U.S. Pat. No. 7,160,574 and which claims the benefitof priority to U.S. Provisional Patent Application Ser. No. 60/406,602,filed Aug. 28, 2002. The entire disclosure of each of the applicationslisted in this paragraph are incorporated herein by specific referencethereto.

FIELD OF INVENTION

This invention relates to pipe linings, and more specifically tomethods, processes, composition, systems and apparatus used to prepareand place protective barrier coatings inside of lead or copper drinkingwater type pipes while the water pipes are left “in place” withouthaving to dismantle the water pipes, so that applied coatings reduceheavy metals, such as lead and copper, from leaching from the installedpipes and fittings to less than approximately 10 μg/L (10 ppb), andwhere pipes can be returned to service from at least approximately 1 toapproximately 4 hours, and preferably within approximately 1 toapproximately 2 hours, and when cured, specific leachates, such as butnot limited to Bisphenol A and Epichlorohydrin will be (less than)<1μg/L (1 ppb) with overall TOC levels measured at (less than)<2.5 mg/L(2.5 ppm).

BACKGROUND AND PRIOR ART

Metal based drinking water pipes and fittings such as those formed usinglead and copper are known to leach toxic materials such as lead andcopper into the drinking water supply. The presence of lead and othermetals in drinking water poses a range of risks to human health,including the retardation of some aspects of child development, theinducement of abortion, and other clinical disorders. The extent ofthese risks has not been quantified at the European Union (EU) scale. Anumber of sampling methods are in use in the EU, the United States andCanada, some of which are inadequate for determining the concentrationsof lead in drinking water at consumers' taps. The new legal standardrequirement in the EU starting in 2013 will require that lead amounts indrinking water up to the point of delivery at the consumers buildingcannot exceed 10 μg/L (10 ppb (parts per billion).

The non-compliance with the EU standards for lead in drinking water hasbeen under-estimated. Emerging data on existing lead and copper basedwater pipes in some European Union countries indicates significantnon-compliance with these standards in, particularly with the 10 μg/L(10 ppb (parts per billion) standard that will become a legalrequirement in 2013. In addition the current interim standard of 25 μg/L(25 ppb) is also exceeded in some locations.

An initial estimate is that 25% of domestic dwellings in the EU have alead pipe, either as a connection to the water main, or as part of theinternal plumbing, or both, potentially putting up to approximately 120million people or more at risk from lead in drinking water within theEU.

Current corrective remedies include the use of chemical additions to thewater supply such as dosing with phosphate-based materials, conventionaldig and replace methods, pull through, moling or slip lining methods andthe use of internally placed resin based coatings.

Internally placed resin based coatings have thus far presented anon-economical solution to the problem of reducing lead levels to theless than the new 10 μg/L (10 ppb) standard. Current coating processesand techniques usually require long cure times and potential leachatescoming from the coating especially when the coatings are subject to highsurface area of pipe wall to water volume in small diameter pipingsystems. For example, pipes less than approximately 50 mm (2″) indiameter and are tested accordingly for leachates.

It is common that the internal diameter of service pipes range fromapproximately 12 mm (½″) to approximately 50 mm (2″) ie: having highsurface area of pipe wall to water volume. In order to not restrict theflow of the liquid through the coated small diameter pipe, that is pipesthat have an interior diameter, ID, in the ranges of approximately 12 mm(½″) to approximately 50 mm (2″), the placed linings typically range inthickness from an average of approximately 100 microns (4 mils) toapproximately 400 microns. (16 mils) Thin set linings, in more or lessthe above stated range of thickness, can be prone to the applicationproblem of pin holing occurring in the uncured coating as well as beingcontaminated with free lead particulates during the application andcuring stage, making compliance to the 10 μg/L (10 ppb) maximum leadcontent in drinking water standard difficult and potentially impossibleto achieve. This invention overcomes these problems.

The use of compression fittings, in-line connectors or couplings andin-line valves are common in the industry. However, when these in-lineconnectors and valves are used, pipe ends and exterior portions of thepipe within the fittings maybe left exposed, leaving direct water tometal contact.

In the United Kingdom, products that come into contact with publicdrinking water must conform to various regulations including DrinkingWater Inspectorate Regulation 31. Regulation 31 of the Water Supply(Water Quality) Regulations 2000 implements Article 10 of the Council ofthe European Union Drinking Water Directive (DWD) in England and Walesfor all chemicals and construction products used by water undertakers,from the source of the water, up to the point of delivery to theconsumer's building. This regulation sets out how approvals can be givento such construction products and materials that do not prejudice waterquality and consumer safety.

Article 10 of the DWD requires Member States shall take all measuresnecessary to ensure that no substances or materials for newinstallations used in the preparation or distribution of water intendedfor human consumption or impurities associated with such substances ormaterials for new installations remain in water intended for humanconsumption in concentrations higher than is necessary for the purposeof their use and do not, either directly or indirectly, reduce theprotection of human health. Under Article 10, the interpretativedocument and technical specifications pursuant to Article 3 and Article4 (1) of Council Directive 89/106/EEC of 21 Dec. 1988 on theapproximation of laws, regulations and administrative provisions of theMember States relating to certain construction products shall respectthe requirements of this Directive.

Piping systems, valves and fittings such as those used as communicationand supply lines servicing buildings and within commercial buildings,apartment buildings, condominiums, as well as homes and the like thathave a broad base of users that may be exposed to water that may betainted by the leaching of metals such as lead and copper that haveleached into the water supply at levels deemed to pose possible healthconcerns is the target of this invention.

Present corrective remedies include the use of chemical additions to thewater supply such as dosing with phosphate-based materials, conventionaldig and replace methods, pull through, moling or slip ling and the useof internally placed resin based coatings. When internally placedcoatings are used they attempt to coat the interior of the pipe butleave pipe ends uncoated, internal fittings uncoated and the exterior ofpipe sections that lay within internal fittings areas that are exposedto drinking water, uncoated. These uncoated areas when exposed todrinking water will continue to leach metals such as lead and copperinto the water supply. Corrective measures taken by adding phosphates tothe drinking water to reduce lead from leaching from substrate materialsis presently a common practise in the United Kingdom (UK). However,phosphates have been identified as being scarce and resources are beingdepleted rapidly on a worldwide basis.

The UK places phosphate into the public water supply to reduceplumbosolvancy (dissolution of lead from old pipework) and has usedphosphate dosing ranges from 0.5-1 mgP/L in low alkalinity areas to1-1.5 mgP/L in high alkalinity areas. Most water is dosed with phosphatebecause it is currently not practicable to target properties with leadsupply or internal plumbing. Taking 1 mgP/L as an average and 17395ML/day into supply equates to about 15,000 tP₂O₅/y. To put this incontext, the UK's Department for Environmental, Food and Rural Affairs(Defra (2011)) reports the total phosphate fertiliser use in the UK isabout 200,000 tP₂O₅/y. There are additional problems with using presentthermoset resin based coating systems. It is widely known that thermosetresin based coating systems do not readily complete cure at ambienttemperatures, leaving un-reacted organic moieties and complexesavailable for water extraction or leaching. This leaching can be furthercompounded with the use of chlorinated water.

Thus, the need exists for a solution to deliver a protective coatingsystem that protects the pipe and fittings, from the effects ofcorrosion and reducing metals from unacceptable levels from leachinginto the water supply, without the need to fully disassemble the pipefrom the fittings wherein the coating is placed in a single coatoperation. A further need exists wherein the use of phosphates used, indosing the water to reduce lead and metals leaching, can be reduced orreplaced, thereby reducing demand on this scarce and depleting resource.

Present methods to accelerate the cure of lining materials, once placedinside a pipe may involve the use of hot water or steam circulatedthrough the piping system. In these present systems the coating isseparated from the steam or water by a flexible membrane or the watercuring stage is initiated only after the coating has reached its B stageof curing.

U.S. Pat. Nos. 5,622,209 and 5,007,461 and 5,499,659 to Naf eachgenerally require long pipe system down times before piping systems canbe returned to service. Generally, the patents describe methods thatinclude “blowing through” the coating in which air was left to streamover the uncured coating “for a further 30 minutes, and the conduit wassealed at the top and bottom at the end of the blowing period. Two dayslater, the conduit was reconnected to the network and thoroughly flushedbeforehand.” The Naf patents refer to adducts but not phenol free andplasticizer free amine adducts added to the curing agent. There is nomention in these references of curing with water or moisture contact.Phenol free and plasticizer free amine adducts were not commerciallyavailable at the time of the 1988 to 1995 filing dates of the Nafpatents.

The Pasteur Document dated 2002, associated with Naf, references a 48hour cure time.

U.S. Pat. No. 5,707,702 to Brady describes a coating having a pot life(working time not cure) of 1-4 hours and in the embodiment says left tocure for 24 hours. These embodiments do not describe the use of phenolfree and plasticizer free amine adducts.

There is no mention in these references of curing with water or moisturecontact.

U.S. Pat. Nos. 7,160,574 and 7,517,409 and 7,858,149, 8,033,242 and8,026,783 to Gillanders et al, assigned to the same assignee as thesubject invention, which are incorporated by reference, describe pipecoating systems and methods that all refer to restoring piping systemsto services within times from less than 24 to 96 hours, but do notreference the use of phenol free and plasticizer free amine adductsadded to the curing agent or using water or steam, in the curing stage.

U.S. Pat. Nos. 6,739,950 and 7,041,176 to Kruse do not mention the useof phenol free and plasticizer free amine adducts added to the curingagent or water cure of the barrier coatings. Curing requires at leastday long cure times and high cure temperatures. For example, Kruse '176describes a 24 hour time period for curing their coatings. Additionally,each of the Kruse references require high heat on pipe 100-120° F.(38-49° C.), while the subject invention requires substantially lowerair temperatures while yielding much quicker cure times.

The U.S. Navy Research Document 1997, entitled: Control of Lead inDrinking Water, epoxy requires 12-18 hours of hot air to cure and, nomention of using moisture to cure. Furthermore, there is no mention ofthe use of phenol free and plasticizer free amine adducts added to thecuring agent.

The U.S. Military Standard, 2001—Public Works Bulletin 420-49-35requires 24 hour cure with 75° F. (24° C.) air, there is no mention ofusing moisture while curing the coating and there is no mention of theuse of phenol free and plasticizer free amine adducts added to thecuring agent.

U.S. Pat. No. 4,966,790 to Iizuka describes examples which show longtime lines to cure, with a minimum of 24 hours of air cure prior to awater cure stage. None of the curing agents describe the use of phenolfree and plasticizer free amine adducts, no disclosure of toxicologicaldata. The epoxy described in Iizuka, after 24 hours, prior to the watercuring stage would have passed its plastic state ie A-Stage of curing.

U.S. Pat. No. 8,053,031 to Stanley describes the use of an anhydrideintroduced into the resin, which is not the use of a phenol free andplasticizer free amine adduct added to the curing agent as the subjectinvention practises. Stanley '031 describes in Table 1 contained in the'031 patent, using a measurement of BPA being leached from the curedepoxy after 2 days at 100 μg/L (100 ppb) and at 20 μg/L (20 ppb) in the2 examples given. This reference makes no mention of epichlorohydrin orTOC levels, which is required under current regulations, there is alsono data to demonstrate the effects of the coating over a lead substrate.

U.S. Published Patent Application 2010/0266764 to Robinson et al.describes a polyurethane coating technique for pipe lining, which has arapid setting of 3 to 6 minutes. However, this process would not resultin coating all of the interior surfaces of the pipes, as well as causingclogs inside the pipe because it sets so quickly. This type of coatingcannot pass through intersections and valves and fittings withoutclogging. Also, polyurethane based coatings are not known to meettoxicology requirements for small diameter drinking water pipes (such asthose having an ID of 2 inches (or 50 mm)) or less in size, that can beplaced in-situ and returned to service having contact with potable waterwithin 12 hours or less.

SUMMARY OF THE INVENTION

A primary objective of the invention is to provide methods, processes,compositions, systems and devices for placing a barrier coating to theinterior diameter (ID) of a drinking water pipe section and/or drinkingwater piping systems that can include certain fittings where the coatingcan be placed to the outside diameter (OD) of exposed ends of smalldiameter pipes within fittings, in a single coat operation, so that thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals such as lead andcopper into the drinking water supply.

A secondary objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals by initially preparing theinterior walls of the pipes, interior walls of in-line fittings andvalves, and outer surfaces of exterior ends of pipe portions within thefittings/valves to receive the barrier coating.

A third objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals in one operation.

A fourth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals in a cost effective and efficientmanner.

A fifth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals which is applicable to smalldiameter piping systems having an interior diameter from at leastapproximately 12 mm.

A sixth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, in a single operation which isapplied to pipes, valves and fitting “in place” (in-situ) minimizing theneed for opening up walls, floors ceilings, or grounds.

A seventh objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, in a single operation, whereonce the existing piping system is restored with a durable barriercoating, the common effects of corrosion from water passing through thepipes, valves and fittings will be delayed.

An eighth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including the leaching of metals, in a single operation, toclean out blockage where once the existing piping system is restored,users will experience an increase in the flow of water, which reducesenergy cost, to transport the water based on enhanced hydrauliccapabilities giving greater water flow through the pipes.

A ninth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including the leaching of metals, in a single operation, wherecustomers benefit from the savings in time and expenses associated withthe restoration of an existing piping system or section.

A tenth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, in a single operation, wherecustomers benefit from the economical savings associated with therestoration of an existing piping system, since walls, ceilings, floors,and/or grounds are not always required be broken and/or cut through asoccurs with existing restoration processes.

An eleventh objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, in a single operation, whereincome producing properties experience savings by remaining commerciallyusable, since operational interference and interruption ofincome-producing activities is minimized.

A twelfth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including the leaching of metals in a single operation, andwhere health benefits increase since water to metal contact is reducedby the barrier coating reducing the leaching of metallic and potentiallyother harmful products from the pipe, valves and fittings into the watersupply such as but not limited to lead from solder joints, lead pipes,lead from other substrates and any excess leaching of copper, iron orlead and the like.

A thirteenth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals from in pipes, valveand fittings, in a single operation where the pipes, valves and fittingsare being restored and repaired, in-place, thus causing less demand fornew metallic pipes and parts, which are non-renewable resources.

A fourteenth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals, in a singleoperation, using a less intrusive methods of repair where there is lesswaste and a reduced demand on landfills.

A fifteenth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including the leaching of metals in a single operation, andwhere the process uses specially filtered air reducing impurities fromentering the piping system during the coating process.

A sixteenth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, in a single operation, and wherethe equipment used operates safely, cleanly, and efficiently in hightraffic areas.

A seventeenth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including the leaching of metals, in a singleoperation where the barrier coating material can be placed in a varietyof piping environments and operating parameters such as but not limitedto a wide temperature ranges, at a wide variety of airflows and airpressures and the like.

An eighteenth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals, in a singleoperation, where the barrier coating material and the process isfunctionally able to deliver turnaround of a restored piping system toservice within at least approximately 1 to 2 hours.

A nineteenth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including the leaching of metals, in a singleoperation, and where the barrier coating material is meets toxicologicaland other standards required by NSF (National Sanitation Foundation)Standard 61 Section 5, UK's Drinking Water Inspectorate Regulation 31,British Standard 6920, EN 12873-2:2005, the Council of the EuropeanUnion Drinking Water Directive or equivalents for use in domestic watersystems where pipes have an internal diameter from at leastapproximately 12 mm (½″) and the in-place field (in-situ) applied curingperiod is at least approximately 1 to approximately 2 hours.

A twentieth objective of the invention is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,placing the coating through fittings and valves to reduce pipe, valve,fitting and substrate contact with drinking water, whereas the barriercoating provides a protective barrier coating reducing the effects ofcorrosion including leaching of metals, the interior of pipes havingdiameters from at least 12 mm is prepared using dry particulates, priorto coating the interior pipe walls.

A twenty first objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals, without having tosection off small sections of piping for cleaning and coatingapplications.

A twenty second objective of the invention is to provide methods,processes, compositions, systems and devices for cleaning the interiorsof an isolated piping system in a single pass run operation.

A twenty third objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, placing the coating through fittings and valves to reduce pipe,valve, fitting and substrate contact with drinking water, whereas thebarrier coating provides a protective barrier coating reducing theeffects of corrosion including leaching of metals in a single pass runoperation.

A twenty fourth objective of the invention is to provide methods,processes, compositions, systems and devices for providing a barriercoating inside, to the exterior and to exposed ends of small diameterpipes, that uses a hydrophobic lining material which can be cured withair alone or in combination with water or steam without the need of aflexible membrane that separates the uncured barrier coating from thewater or steam used during the curing process.

A twenty fifth objective is to provide methods, processes, compositions,systems and devices for providing a barrier coating inside, to theexterior and to exposed ends of small diameter pipes, that adds phenolfree and plasticizer free adducted amines in the curing agent of thecoating to reduce leaching levels of BPA and Epichlorhydrin.

A twenty sixth objective is to provide methods, processes, compositions,systems and devices for providing a barrier coating inside, to theexterior and to exposed ends of small diameter pipes which uses a blastmedia cleaning process in the presence of lead substrates, whereblasting media can include at least one of: calcium, silica, garnet,alumina, silicone, sodium, sodium bicarbonate, glass, crushed nutcasings, plastic abrasives both thermoset and thermoplastic such as butnot limited to, plastics, acrylic, urea, melamine, thermoplastic, bioplastic, polyamide, nylon, thermosetting polymer or cellulose which allcan be used alone, in combination or in part with other abrasivematerials.

A twenty seventh objective is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,that uses, which can stabilize the lead substrate in lead water pipesafter the cleaning process with an in-situ application of a liquid leadstabilizer that is comprised of water soluble phosphate wherein inphosphates can include, phosphates, calcium orthophosphate, calciumphosphate, trisodium phosphate, monocalcium orthophosphate, tricalciumorthophosphate and the like. The stabilizer can have a pH of at least 8.

A twenty eighth objective is to provide methods, processes,compositions, systems and devices for providing a barrier coatinginside, to the exterior and to exposed ends of small diameter pipes,which can stabilize the lead substrate in lead water pipes after thecleaning process with an in-situ application of an anionic or nonionicsolution.

A twenty ninth objective is to provide methods, processes, compositions,systems and devices for providing a barrier coating inside, to theexterior and to exposed ends of small diameter pipes, which can reducelead leaching, from a substrate containing lead (ie: lead water pipesand fittings containing lead), to less than approximately 10 μg/L (10ppb), preferably less than approximately 1 μg/L (1 ppb).

A thirtieth objective is to provide methods, processes, compositions,systems and devices for providing a barrier coating inside, to theexterior and to exposed ends of small diameter pipes, which can reducelead leaching, from a substrate containing lead (ie: lead water pipes),to less than approximately 10 μg/L (10 ppb) preferably less than 1 μg/L(1 ppb) which allows for a reduction of the practice of using phosphatesto reduce lead leaching.

A thirty first objective is to provide methods, processes, compositions,systems and devices for providing a barrier coating inside, to theexterior and to exposed ends of small diameter pipes, where the barriercoating will create at least an approximately average 100 micron (4mils) covering to the inside of the piping system and fittings and willseal leaks spanning openings up to approximately 125 mils.

The piping systems, valves and fittings covered by this invention can bemade of various materials such as lead, galvanized steel, black steel,brass, copper or other materials such as PVC, CPVC and compositesincluding plastics, where a barrier coating lining is used as analternative to pipe replacement or repair and reduces use of chemicallydosing water supplies which are commonly used to reduce metals leachingfrom the water carrying pipes into the drinking water supply.

The novel coating process can be completed, without having to physicallyremove and replace all the pipes, where the interior diameters of thepipe are coated and if the pipe is located within fittings the exteriorends and the piping's outside diameter subject to water exposure,contained within fittings and valves, can be coated in a singleoperation. If needed, the novel coating is capable of being applied inmultiple layers.

The coating material when cured “in-place”, is capable of allowing thecoated pipes, fittings and valves to be placed back into service in aperiod of at least approximately 1 hour to approximately 4 hours,preferably at least approximately 1 hour to approximately 2 hours. Thecoating is further suitable to application to potable water carryingpipes having an internal diameter from at least approximately 12 mm(12″).

With the novel coating and coating process, leaching of toxic compounds,such as Bisphenol A (BPA) and Epichlorohydrin will be less thanapproximately 1 μg/L from the cured coating, when the coating is curedand then soaked in an equivalent of 1 liter of water against theestimated internal diameter surface area of a pipe having an internaldiameter of at least approximately 12 mm (an approximate SA:Vol of 33.33dm⁻¹). Testing of the barrier coating has been conducted, when thecoating is applied and cured within its specified curing period i.e.: aperiod of at least approximately 1 hour to approximately 4 hours,preferably approximately 1 to approximately 2 hours and then tested forBisphenol A and Epichlorohydrin and Total Organic Compounds.

Testing methods and thresholds are those described in UK's DrinkingWater Inspectorate Regulation 31, British Standard 6920:2000 testedaccording to EN 12873-2:2005, EU Drinking Water Directive (DWD) CouncilDirective 98/83/EC and EU Construction Products Directive (89/106/EEC)for field applied coatings. Based on three, 72 hour±1 hour soaks with awater temperature of at least 23° C.±2° C., Bisphenol A andEpicholohyrin extractables will be measured at less than approximately 1μg/L (1 ppb), TOC extractables have been measured at less thanapproximately 2.5 mg/L (2.5 ppm). When the coating is placed and curedon a lead substrate and tested for lead leaching after a 72 hour±1 hourperiod of stagnation, lead in leachate has been measured to be less thanapproximately 10 μg/L (10 ppb), and has been measured to be less thanapproximately 1 μg/L (1 ppb).

In particular, when the preferred method of substrate preparation isconducted portions of previously applied coatings/lead inhibitors thatare loose will be removed in a brush off approach leaving adherentresiduals on the substrate surface.

Additionally, the preferred coating conforms to BS 6920:2000 tested toEN 12873-2:2005, for a) odour and flavour of water, b) appearance ofwater, c) growth of aquatic microorganisms, d) extraction of substanceswhich would be of concern to public health and e) extraction of metals,for contact with drinking water with temperatures up to 85° C.

An embodiment of the invention provides for methods, processes,composition, systems and apparatus used to prepare and place aspecialized 2 part thermoset resin as a protective barrier liningmaterial coating, inside of drinking water pipes, valves and fittingsformed from materials that leach toxic metals such as lead and copperinto the drinking water. The novel lining material can coat interiorwalls of pipe sections and piping systems, where pipes can have bends,t″ intersections, varying diameters and can also have in-line pipeconnectors, or valves where pipe ends and the exterior walls (outsidediameters) of the pipes which exposed to water within the valve orfittings.

The novel protective barrier coating can be placed inside the pipes,valves or fittings while “in-place”, wherein the protective barriercoating can be applied under positive pressure in a single operation tothe interior walls of pipes, fittings and valves and pipe ends and theexterior portions of pipes where pipe ends and exteriors are situatedwithin fittings of small diameter pressurized and non-pressurized metaland plastic type pipes and fittings.

The types of water service lines that can be treated and coated caninclude but is not limited to hot water lines, cold water lines, potablewater lines, fire sprinkler lines, natural gas lines, drain lines,pressurized and non-pressurized pipes and the like. Such service linescan be located both outside or underground and/or used in multi-unitresidential buildings, office buildings, commercial buildings, schools,hospitals and single family homes and the like.

An embodiment can include a 2 part thermoset lining material, havinghydrophobic qualities, can be cured in-place using warm air, fromapproximately 10° C., alone or in combination with water or steam or acombination of such without the need for a membrane barrier separatingthe water or steam from the lining material/coating, wherein the wateror steam curing stage can be initiated while the coating material isstill in its A-Stage of curing, being an early stage in the reaction inwhich the coating material is fusible and still soluble in certainliquids.

The base-curing agent can incorporate an amine adduct where the adductis a phenol free and plasticizer free type. In the presence of a leadsubstrate, the process can incorporate lead stabilizing agents, selectblasting abrasives and applications that use filters to reduce sedimentand the fixed gas content of water used in the water curing stage.

The invention described here overcomes the problems associated withpresent methods, application and coatings to provide an economicalsolution meeting economical turn-around times i.e.: fast cure, whenapplied to small diameter pipes, having internal diameters from at leastapproximately 12 mm, meeting at least the current regulatoryrequirements, while providing a protective coating that can be appliedin a single coating operation. Such coatings will provide a protectivebarrier coating to the interior of the pipe and can be applied throughfittings where pipe ends and the exterior of the pipe, within thefitting which are exposed to the drinking water.

In order to avoid the expense and inconvenience of replacing the pipesand locating these fittings and replacing them there is a need for theinvention which is to provide a protective bather coating that can beapplied to the inside of a pipe but can also be applied through thefittings, coating the interior of the pipe and coating the exposed pipeends and the exterior portions of the pipes which are exposed to thedrinking water that are contained within a fitting, in a single coatingoperation and being cured and be returned to service in at leastapproximately 1 to approximately 2 hours and reducing lead levelsleaching into the water supply to less than 10 μg/L (10 ppb).

When the lining material is being applied the invention can usepreferred methods and materials to reduce the effects of pin holing inthe coating. When being applied to a lead substrate the preferredmethods can reduce free lead particulates on the substrate fromcontaminating the lining material when the lining material, in its fluidstate, is being placed and then cured on the substrate. The novelmethods, process, compositions and systems of pipe restoration preparesand protects small diameter piping systems such as those within theinterior diameter range of from at least approximately 12 mm and caninclude straight and bent sections of piping from the effects of watercorrosion, erosion and electrolysis thus reducing metals and otherleachates from leaching into the water supply and extending the life ofsmall diameter piping systems.

The barrier coating used as part of the novel process, method andsystem, can be used in pipes servicing potable water systems, meetingthe toxicological and other standards described in NSF (NationalSanitation Foundation) Standard 61, Section 5, UK's Drinking WaterInspectorate Regulation 31, British Standard 6920:2000, EN 12873-2:2005,the Council of the European Union Drinking Water Directive orequivalents. The novel method, process and system allows for barriercoating of interior and exterior parts of pipes, pipe ends, interior ofvalves and in-line fittings, in a single operation to hot or coldpotable water lines.

The novel method of application of the barrier coating is applied topipes, fittings and valves “in-place” eliminating the traditionaldestructive nature associated with a re-piping job. Typically one systemor section of pipe can be isolated at a time and the restoration of thesystem or section of pipe can be completed in less than one day(depending upon the size of the project) and type of application)wherein the coated pipe, fitting or valves are capable of being placedback into water service in at least approximately 1 to approximately 2hours.

The novel application process and the properties of the coating ensurethe interior of the piping system is fully coated. Thermoset coatingsare characterized by their durability, strength, adhesion and chemicalresistance, making them an ideal product for their application as abarrier coating on the inside of small diameter piping systems, valvesand fittings. The barrier coating will create at least an approximatelyaverage 100 microns (4 mils) covering to the inside of the piping systemand will seal leaks spanning openings up to approximately 125 mils.

The novel method and system of corrosion control by the application of abarrier coating can be applied to existing piping systems in-place, withno need to remove in-line fittings and valves in the same operation.

The invention includes novel methods and equipment for providing barriercoating corrosion and a repair method for placement of a barrier coatingand sealing leaks to the interior walls of small diameter piping systemsincluding, coating exterior ends of pipes within fitting and coatinginterior surface areas of valves and in-line fittings in the sameoperation. The novel process method and system of internal leak repairand corrosion control can include at least three basic steps: Air dryinga piping system to be serviced; preparing the piping system using anabrasive agent and applying the barrier coating to a selected coatingthickness inside the pipes, fittings and valves.

The novel invention can also include additional preliminary steps of:diagnosing problems with the piping system to be serviced, measuringlead levels in the water prior to coating, planning and setting up thebarrier coating project onsite, inducting the mixed coating prior toplacement, placement of the coating, curing the coating using air aloneor with water or steam, or combination thereof. Finally, the novelinvention can include a final end step of evaluating the system afterapplying the barrier coating and re-assembling the piping system and ananalysis of the lead content in the drinking water may be completedafter system has been restored to service.

Further objects and advantages of this invention will be apparent fromthe following detailed description of the presently preferredembodiments which are illustrated schematically in the accompanyingdrawings.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A, 1B and 1C shows the fifteen (15) general steps for the productapplication of the novel thermoset lining to the piping sections/systemfor applying the novel barrier coating leak sealant.

FIGS. 2A, 2B, 2C and 2D shows a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating.

FIG. 3 shows a flow chart of the set-up for the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining the disclosed embodiments of the present invention indetail it is to be understood that the invention is not limited in itsapplication to the details of the particular arrangements shown sincethe invention is capable of other embodiments. Also, the terminologyused herein is for the purpose of description and not of limitation.

This application is a Divisional Application of U.S. patent applicationSer. No. 14/011,260 filed Aug. 27, 2013, now allowed, which is aDivisional Application of U.S. patent application Ser. No. 13/566,377filed Aug. 3, 2012, now U.S. Pat. No. 8,524,320, which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.61/595,794 filed Feb. 7, 2012, and this application is aContinuation-In-Part of U.S. patent application Ser. No. 13/210,659filed Aug. 16, 2011, now U.S. Pat. No. 8,887,660, which is a DivisionalApplication of U.S. patent application Ser. No. 12/378,670 filed Feb.18, 2009, now U.S. Pat. No. 8,206,783, which is a Divisional Applicationof U.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, nowU.S. Pat. No. 7,517,409, which is a Divisional Application of U.S.patent application Ser. No. 10/649,288 filed Aug. 27, 2003, now U.S.Pat. No. 7,160,574, and which claims the benefit of priority to U.S.Provisional Patent Application Ser. No. 60/406,602, filed Aug. 28, 2002,all of which are incorporated by reference.

The invention described here overcomes the problems associated withpresent methods and application of coating materials to provide aneconomical solution, meeting economic turnaround times i.e.: fast cure,in small diameter pipes where the coating is subject to meeting thecurrent regulatory requirements while providing a protective coatingthat can be applied in a single coating operation that will coat theinterior of the pipe and coat through fittings where lead pipe ends andthe exterior of the lead pipe, within the fitting, are exposed to thedrinking water.

In order to avoid the expense and inconvenience of locating thesefittings and replacing them there is a need for a methodology to providea protective coating that can be applied through the pipe or fitting,coating the interior of the pipe and, the pipe ends and the exterior ofthe pipe where pipes are exposed within the fitting, in a single coatingoperation.

The invention uses a two component thermoset coating system specificallydesigned for use in small diameter pipeline applications. The materialhas certain thixotropic characteristics for enablement of applicationinto small diameter pipes having an interior diameter from at leastapproximately 12 mm (½″) to approximately 102 mm (4″), and preferably inthe range of approximately 12 mm (½″) to approximately 50 mm (2″), andbeing able to be applied through the interior of pipes and throughin-line fittings and valves in the same operation.

Correctly applied, the coating provides corrosion protection, protectionagainst pinhole leaks in the piping system and protection againstleaching of substrate materials into the drinking water. The coating isengineered to be applied to both metallic and non-metallic pipes andfittings. Metallic pipes/fittings would include those made of steel,iron, copper, lead, stainless steel, galvanized steel, brass, aluminumand various alloy combinations. Non-metallic pipes/fittings wouldinclude those made of materials such as: CPVC (chlorinated polyvinylchloride), PVC (polyvinyl chloride), PEX (cross-linked polyethylene), PB(polybutylene), ABS(acrylonitrile butadiene styrene), HDPE (high-densitypolyethylene) and concrete.

The coating material can be injected into small diameter pipes or pipingsystems, which may have valves or in-line fittings, using substantiallymoisture free and substantially oil free filtered compressed air.

The application of the lining material is a combination of material andmethodology, times and temperatures, resulting in a protective barriercoating providing a minimum average of no less than an approximate 100microns (4 mils) coverage inside the pipe. The focus of the barriercoating is to provide a protective barrier coating to the interior pipewall to assist in reducing water to metal contact and reduce leadleaching into the drinking water supply from exposed substrate surfaceswhich come into contact with drinking water, so that lead leaching willmeasure less than approximately 10 μg/L (10 ppb), preferably less than 1μg/L (1 ppb) after the process is completed.

Coverage verification may be completed by a visual inspection and bymeasuring at accessible points in the piping system. Water flow ratechecks can be conducted before and after the coating application.

The curing time of the coating is at least approximately 1 hour toapproximately 2 hours, cured using air alone or with water or steam or acombination of such curing methods varying on several factors such asinduction and temperature times, range of application temperatures andapplication conditions.

FIGS. 1A, 1B and 1C shows the fifteen (15) general steps for the productapplication of the novel thermoset lining to the piping sections/systemfor applying the novel barrier coating leak sealant. The fifteen (15)general steps will now be described.

1) Prepare pre coating water analysis.

-   -   Interview on site engineering staff, property managers, owners        or other property representatives as to the nature of the        challenges.    -   Evaluation of local and on-site water chemistry for hardness and        aggressive qualities, knowledge of metal leaching into water        supply.    -   Engineering evaluation, if necessary, to determine extent of        present damage to the wall thickness of the piping, overall        integrity of the piping system and water sampling for specific        determinants such as lead.    -   Additional on-site testing of water, piping system, if        necessary, identifying leaks or the nature or extent of leaking.    -   Corrosion control proposal development for client, including        options for pipe and fitting replacement where necessary.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660 which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

2) Prepare job details

-   -   Complete contract development with client.    -   Commence project planning with site analysis crew, project        management team, and engineering/maintenance staff.    -   Plan delivery of the equipment and supplies to the worksite.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012,U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660 which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

3) Transport to job

-   -   Complete equipment and supply delivery to site.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660, which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

4) Prepare access to piping system or section

-   -   This step depending on location of pipe may involve for example,        using line locators, locating connection of communication pipe        off of water main, location of curb tap and supply pipe, access        where required. If pipe section is in a building, may involve        locating mains, distribution lines, cutting access panels if        required.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, and U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660, which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

5) Isolate Piping Section—

-   -   When piping section to be isolated has been identified it can        then be and isolated from the water source the piping        section/system to be treated. Isolation may involve the use of        bypass systems, use of control valves, pipe freezing or other        techniques to permit isolation of the system or section to be        worked on.    -   This step is further described in part, in the subject        inventor's previous patent applications which include U.S.        Provisional Patent Application Ser. No. 61/595,794 filed Feb. 7,        2012,U.S. patent application Ser. No. 13/210,659 filed Aug. 16,        2011, now U.S. Pat. No. 8,887,660, which is a Divisional        Application of U.S. patent application Ser. No. 12/378,670 filed        Feb. 18, 2009, now U.S. Pat. No. 8,206,783, which is a        Divisional Application of U.S. patent application Ser. No.        11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409,        which is a Divisional Application of U.S. patent application        Ser. No. 10/649,288 filed Aug. 27, 2003, now U.S. Pat. No.        7,160,574, and which claims the benefit of priority to U.S.        Provisional Patent Application Ser. No. 60/406,602, filed Aug.        28, 2002.

6) Drain Piping Section/System

After the piping section has been isolated, the section can be drainedof water. The compressor can be hooked up to at least one opening of thepiping section and filtered pressurized air can be blown through thepipe which can assist in the draining process.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660, which is a Divisional Application of U.S. Patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

7) Dry Piping Section/System

Prior to the cleaning/abrading application, the pipes shall berelatively dry and relatively free from standing water. This is achievedby drying the inside of the piping section/system with heated, filteredcompressed air which flows through the pipe section/system.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660, which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

8) Clean and Abrade Piping Section/System

The cleaning process utilizes compressed air and selected abrasivesbeing applied to the inside of the piping section/system. Attach thecompressor to the sander which is connected to the open end of thepiping section. At the exit end of the piping section, attach the vacuumcollector. The choice of the abrasive, grit size and type, used inconjunction with the sander and compressed air are at the discretion ofthe contractor. Various abrasive types can be used depending on localsupply. Pressurized air up to approximately 0.755 m³/s (1600 CFM) and upto approximately 1379 kPa (200PSI) into one end of the pipe for dryingand cleaning the interior, generating a vacuum drawing air up toapproximately 0.519 m³/s (1100 CFM) in a second end of the pipe. Duringthe process there are times the compressor can operate alone or thevacuum can operate alone or they can ideally operate simultaneously witheach other.

This step is further described in part, in the subject inventor'sprevious patent applications which include U.S. Provisional PatentApplication Ser. No. 61/595,794 filed Feb. 7, 2012, U.S. patentapplication Ser. No. 13/210,659 filed Aug. 16, 2011, now U.S. Pat. No.8,887,660, which is a Divisional Application of U.S. patent applicationSer. No. 12/378,670 filed Feb. 18, 2009, now U.S. Pat. No. 8,206,783,which is a Divisional Application of U.S. patent application Ser. No.11/246,825 filed Oct. 7, 2005, now U.S. Pat. No. 7,517,409, which is aDivisional Application of U.S. patent application Ser. No. 10/649,288filed Aug. 27, 2003, now U.S. Pat. No. 7,160,574, and which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.60/406,602, filed Aug. 28, 2002.

It is well known that lead used in fabrication of fixtures or with pipescan leach for a considerable period of time. More to the point of thisinvention is the in-place remediation of lead pipes whereby aspecialized lining material can be placed inside a lead pipe or a pipeand fixtures that contain lead, reducing lead levels so lead leachinginto the drinking water supply from the lead substrate will measureapproximately 10 μg/L or less, reducing or eliminating the need to relyon expensive ongoing passivation or pipe replacement methods to meet themaximum 10 μg/L lead leaching cut off criteria.

In the presence of a lead substrate the invention uses a method ofpreparing the lead substrate that minimizes the removal of the effectsof passivation of the lead that had taken place on the lead substratewherein the lining material while being placed will pick up less freelead residuals. Pipes and fittings containing lead in their make-up thatare prepared and lined by this invention will leach less thanapproximately 1 μg/L of lead without the need for ongoing passivation.

The invention uses a preferred method of preparing the lead substratewherein the substrate is prepared in such a manner combined with themethods, apparatus and application of the coating materials reduces theneed for the ongoing use of corrosion inhibitors such as phosphate-basedmaterials and reduces the time for lead leaching to fall below thedesired “steady state” of less than 10 μg/L. See TABLE 1

TABLE 1 describes the Lead Leaching Results for a substrate lead pipehaving various surface preparation procedures for non-chlorinated waterpipes. Testing was completed various conditions of lead substrate allpipes were exhumed in service samples, extracted in the UK. Specimen'stested included 1) White Metal—SSPC-SP 5 (NACE 1) Removal of all visiblerust, mill scale, paint, and foreign matter by blast cleaning, untreated2) Lead with inhibitor was an exhumed in service lead line that had beenprotected using a phosphate inhibitor, dried and coated 3) Near WhiteBlast SSPC-SP 10 (NACE 2) Blast cleaning nearly to White metalcleanliness, until at least 95% of the surface area is free of allvisible residues and coated 4) Brush-Off Blast Cleaning SSPC-SP 7 (NACE4)—Blast cleaning of all except tightly adhering residues of mill scale,rust and coatings and coated. Cleaning standards referenced are SSPC,Society for Protective Coatings and NACE is National Association ofCorrosion Engineers. The preferred method focused on Brush-Off BlastCleaning SSPC-SP 7 (NACE 4) standards on lead substrate.

Leaching periods T1 through T3 are 3×72±1 hour leachates periods.Testing on preferred method completed June 2012 by LGC Ltd., QueensRoad., Teddington, Middlesex, TW11 0LY, UK.t Analytical Sciences,Petaluma, Calif., USA, 94952 completed testing on alternative methods inMarch 2012

TABLE 1 Lead μg/L Substrate Preparation to Lead Pipe Lead w/inhibitorPreferred Method Lead pipe treated Previous adherent Leaching −72 hourswith coating remains after per period (T) orthophosphate- brush offstandard Non-chlorinated White Metal Blast based lead inhibitor Nearwhite Blast preparation water No Coating No Coating With Coating WithCoating T1 79,000 μg/L 150 μg/L 6.2 μg/L .17 μg/L T2 94,000  77 37.5<.10 T3 99,000 140 88.7 <.10

Additional leaching testing for lead was completed by LGC Ltd., on thepreferred method using chlorinated water which showed lead levels at T1:<0.10 μg/L, T2:<0.10 μg/L and T3: 0.19 μg/L, all below 1 μg/L, thereporting cut off for British Standard BS 6920.

When lead substrate material is present and in particular when preparingthe substrate of lead pipe, the preferred blast media may range fromthose having a sphere like shape, a low angular profile, a cubicalprofile, to those having a highly angular profile. Abrasive particulatesthat contain in their make up can include at least one of or anycombination of: calcium, silica, garnet, alumina, silicone, sodium,sodium bicarbonate, glass, crushed nut casings, plastic, acrylic, urea,melamine, thermoplastic, bioplastic, polyamide, nylon, thermosettingpolymer or cellulose.

The abrasive particulates can include those in the range ofapproximately 8 to approximately 600 US mesh, preferably in the range of8 to 100 US mesh size and a hardness rating of less than approximately 9Mohs, preferably less than 4 Mohs, and more preferably approximately 1to approximately less than 4 Mohs can be selected.

Abrasives can be injected into the piping system, which if comprised ofa lead substrate, with air pressures of approximately less than 413.685kPa (60 PSI), preferably between approximately 34.47 kPa (5 PSI) andapproximately 310.26 kPa (45 PSI). The lead substrate will not bescarified but peened and ideally portions of previously appliedcoatings/lead inhibitors that are loose will be removed in a brush offapproach leaving adherent residuals on the substrate surface.

Abrasives can be injected into the piping system using compressed air,forced in at an opening of the piping system where the abrasive mediawill be directed over the interior pipe wall with angles of strike ofless than 90°, preferably less than a 30° strike angle, when measuredagainst the pipe wall, while spent abrasives and resulting debris areevacuated via forced compressed air at the entry of the system and avacuum draw at the exit of the piping system.

During the process there are times the compressor can operate alone orthe vacuum can operate alone, ideally they should operate simultaneouslywith each other for a selected time of at least several minutes.Pressurized air up to approximately 0.755 m³/s (1600 CFM) and up toapproximately 1379 kPa (200PSI) into one end of the pipe for drying andcleaning the interior, generating a vacuum drawing air up toapproximately 0.519 m³/s (1100 CFM) in a second end of the pipe.

The spent abrasive and debris are captured in the vacuum/collector atthe piping system exit. Part of the applicator procedure is toindependently air flush the piping system to further remove any loosedebris. Air flushing is a procedure where after the abrading process iscomplete, an independent flush of the piping system using “air only” iscompleted.

Abrading material can be used in a single pass run. The simultaneous useof the air filter vacuum at the exit end, drawing air to assist thecompressor, reduces the negative effects of friction loss in the pipingsystem, enhancing the effects of the sanding and debris removal. In thepresence of lead pipe and fittings the vacuum assists in a moreefficient means of evacuating lead dust and debris. An optional leadstabilizer/passivator can be applied during and/or at the conclusion ofthe cleaning process, prior to the lining process.

9) Heat Piping Section/System

The suggested minimum temperature of the substrate at the onset shouldnot be less than approximately 3° C. (37° F.) Heating the piping sectioncan be achieved by flowing heated filtered compressed air through thepipe section, heated water or steam heating also be used. Heated flowingair ideally in the range of 10° C. to 30° C. (50° F. to 86° F.) can beused. Higher temperatures beyond 30° C. (86° F.) can be used in theprocess. The air can be mechanically heated by a compressor or the useof in-line heaters that are electronically or gas fueled or such as theunit described in U.S. patent application Ser. No. 12/571,561, filedOct. 1, 2009, now U.S. Pat. No. 8,399,813, which is a Continuation inPart of Application of U.S. patent application Ser. No. 12/378,670 filedFeb. 18, 2009, now U.S. Pat. No. 8,206,783, which is a DivisionalApplication of U.S. patent application Ser. No. 11/246,825 filed Oct. 7,2005, now U.S. Pat. No. 7,517,409, which is a Divisional Application ofU.S. patent application Ser. No. 10/649,288 filed Aug. 27, 2003, nowU.S. Pat. No. 7,160,574, and which claims the benefit of priority toU.S. Provisional Patent Application Ser. No. 60/406,602, filed Aug. 28,2002.

Pipe substrate temperature readings can be taken by electronic ormechanical methods. Mechanical means can be a surface type contactthermometer, whereas electronic means can be by the use of a laser typetemperature reading unit.

Temperature readings can be taken ideally where the air exits the pipingsystem and the heat sources can be adjusted accordingly.

10) Prepare and Inject Lining Material

Estimate the amount of lining material required to coat the pipingsection. Mix quantity as required, ideally, mechanical mixers can beused. Induct mixed coating material for at least 1 minute and theninject mixed coating material into the piping system using heatedsubstantially moisture free and substantially oil free filteredcompressed air. Positive air pressure is used to inject the liningmaterial. Depending on pipe ID and lengths and various other factorssuch as the coatings viscosity, pot life and application temperatures.For example, for pipes ranging in ID from 12 mm (½″) to 50 mm (2″) ID,injection pressures can range from about 20 PSI (137.90 kPa) to about 60PSI (413.685 kPa)

Table 2 shows the estimated amount of mixed material required.

TABLE 2 ESTIMATED AMOUNT OF MIXED MATERIAL REQUIRED Approx. PipeInternal Dimension (ID) with coating quantity expressed in mls Length(m) 12 mm 20 mm 25 mm 32 m 38 mm 50 mm 3 100 mls 100 mls 200 mls 200 mls200 mls 300 mls 6 150 150 300 300 400 500 9 200 300 400 500 600 700

If leaks are identified or are suspect and the approximate sizedetermined, the operator can choose to apply the coating materialwithout fillers, if the leak is determined to be approximately >30 milsin size, the operator can decide to add fillers to the coating material,prior to injection into the piping system. Fillers preferably made ofthe same material that comprises the barrier coating can be used. Othermaterials may also be used include: glass flakes, glass fibers, epoxyfibers, mica, clay, silica, cork, plastics, acrylic, urea, melamine,thermoplastic, bioplastic, polyamide, nylon, thermosetting polymer orcellulose.

Such fillers and materials are described in pending U.S. patentapplication Ser. No. 12/813,873 filed Jun. 11, 2010, now U.S. Pat. No.8,343,579, to the same assignee as the subject invention, which is aDivisional of U.S. patent application Ser. No. 12/723,115, now U.S. Pat.No. 8,033,242, which is a Divisional of U.S. patent application Ser. No.11/649,647 filed Jan. 4, 2007, now U.S. Pat. No. 7,858,149 which is aContinuation-In-Part of U.S. patent application Ser. No. 11/246,825filed Oct. 7, 2005, now issued as U.S. Pat. No. 7,517,409, which is aDivisional of U.S. patent application Ser. No. 10/649,288 filed Aug. 27,2003, now issued as U.S. Pat. No. 7,160,574 and which claims the benefitof priority to U.S. Provisional Patent Application Ser. No. 60/406,602,filed Aug. 28, 2002, all of which are incorporated by reference.

The coating and material can be mixed and metered to required amounts asper manufacturer's specifications using a mixer. The barrier coating andfillers are placed into coating carrying/induction tube and inducted aspart of the mixing and curing process prior to application. Theinduction step assists the resin and hardener to better compatibilizebefore injection and placement into the piping system.

The coating with or without fillers as determined can be injected intothe piping system using heated, pre-filtered, substantially moisture andsubstantially oil free compressed air at temperatures, air volumes andpositive pressure levels to distribute the barrier coating throughoutthe areas to be coated, in sufficient amounts, to reduce the water topipe/substrate contact in order to create a barrier coating whichreduces water to metal contact on the inside of the pipe or fitting andif leaks are present, seal the leak in a single operation.

The temperature of the air flow ideally will range from approximately10° C. to approximately 30° C. (50° F. to 86° F.) but can be greater.During this placement or wetting out stage, a vacuum filter can be usedin conjunction with the compressor to assist the wetting out of thecoating material. During this wetting out period a positive pressure andairflow in the piping system must be maintained on the inside of thepipe. Ideally a positive air pressure of at least approximately 1.5 PSI(10.34 kPa) should be applied while the coating material is beingplaced. The coating can be applied to achieve a minimum average coatingthickness of at least approximately 100 microns (4 mils) and can sealleaks up to approximately 125 mils in size.

11) Coating Pipe Lengths and Diameters—

Pipe lengths and corresponding diameters that can be coated (lengthsexpressed in meters) given here as a guide in Table 3, assumes aunidirectional application with no additional entry points. Multidirectional application can be required on longer lengths. Internal pipediameters that can be coated are from at least approximately 12 mm (½″)ID (interior diameter) in size.

TABLE 3 Pipe Diameter and Single Sectional Length Guide Internal PipeUnidirectional Approximate Maximum Diameter Application Single SectionalLength 12-15 mm Yes 20 meters 20-25 mm Yes 30 meters 32-50 mm Yes 35meters

12) Cure Lined Pipe—Cure Step 1—Air Curing Stage:

Once the coating material is placed in the piping system, heated,substantially moisture free and substantially oil free filtered,compressed air is applied to create a neutral or positive pressure,ideally a positive pressure of at least approximately 1.5 PSI (10.34kPa) should be applied over the internal surface of the pipe andthroughout any in-line fittings and valves to set the barrier coatingfor a selected period of time of at least several minutes, wherein thecoating can remain in at least it's A—Stage of cure prior to the wateror steam cure stage is achieved.

The temperature of the air flow ideally will range from approximately10° C. to approximately 30° C. (50° F. to 86° F.) but can be greater. Ifambient air temperatures can be maintained at approximately no less thanapproximately 10° C., (50° F.) then the mechanically heated air flowsmay be eliminated at this stage of the process.

Cure Step 2—Water or Steam Curing Stage:

After the air curing stage is completed, a water or steam cure stage canbe added by passing water or steam or a combination thereof through thelined pipe until the lining has achieved its final cure. If heatedwater, (above approximately 25° C. (77° F.)) is used in the water curingprocess, the addition of a degassing water filter apparatus can be usedto reduce fixed gasses from the heated water. The degassing filter canreduce fixed gasses in the source water. The reduction of fixed gassesin the source water, being used in the curing process, will reduce theamount and effects of air being released from the heated water.Depending on the degree of cure of the placed lining material at thetime of the release of fixed gasses, the lesser amount of fixed gasbeing released from the water lessens the likelihood of surfaceimperfections such as pin holing occurring in the uncured coatingespecially when the coating is at its A stage of cure. Fixed gas contentof the cure water which can include: oxygen, nitrogen, carbon dioxide,hydrogen, ethane, ethane, acetylene, propane and carbon monoxide shouldbe less than 40,000 parts per million per volume (ppmv) and ideally lessthan 25,000 ppmv when tested according to ASTM Method 1946 D.

Water used in the water cure stage can contain sediments or otherforeign matter which when in contact with degassing filters or apparatusor in contact with uncured coating can, depending on size and amount,create potential clogging or contamination and should be reduced.

Ideally, sediment filters used to clean the water used in the curingprocess shall be capable of reducing sediments to at least anapproximate 5 microns in size.

The barrier coating can be cured in a period of at least approximately 1hour to approximately 4 hours. Filters can be obtained from GEAppliances, Louisville Ky., 40225.

13) Post Cure Inspection

After completion of cure, the lined pipe shall be visually inspected forcure and quality. The desired minimum average thickness of the coatinginside the pipe will be of no less than approximately 100 microns (4mils) with full 360° coverage. A final water flow rate check can beconducted. A water flow check can be measured with a calibrated vesselor a water flow meter.

14) Disinfection, Flushing and Waste Water

Prior to reinstatement, the coated pipe and fittings can be disinfectedin accordance with local water supplier guidelines. In the event thewater supplier has no disinfection procedures, an optional minimum ofapproximately 5 minutes of a fresh water flush may be completed. Localmain water supplies can be used.

15) Conduct Post Coating Water Analysis

The water test can be conducted to determine the effectiveness of thecoating over suspect substrate materials that may have been in thepiping system. Ideally specific metals testing can be conducted first onsite and if additional testing is required then established samplingprotocols can be followed for on-site collection and analysis.

FIGS. 2A, 2B, 2C and 2D show a detailed process flowchart using thesteps of FIG. 1 for providing the barrier coating leak sealant. Theseflow chart figures show a preferred method of applying a novel barriercoating leak sealant for the interior of small diameter piping systemsfollowing a specific breakdown of a preferred application of theinvention.

FIGS. 2A-2D are further described in detail in reference to parentpatent applications U.S. patent application Ser. No. 13/210,659 filedAug. 16, 2011, now U.S. Pat. No. 8,887,660, which is a DivisionalApplication of U.S. patent application Ser. No. 12/378,670 filed Feb.18, 2009, now U.S. Pat. No. 8,206,783, which is a Divisional Applicationof U.S. patent application Ser. No. 11/246,825 filed Oct. 7, 2005, nowU.S. Pat. No. 7,517,409, which is a Divisional Application of U.S.patent application Ser. No. 10/649,288 filed Aug. 27, 2003, now U.S.Pat. No. 7,160,574, and which claims the benefit of priority to U.S.Provisional Patent Application Ser. No. 60/406,602, filed Aug. 28, 2002,all of which are incorporated by reference.

Components in FIG. 3 will now be identified as follows:

IDENTIFIER EQUIPMENT 100 Compressed, Air Supply Outfitted withAftercooler, Water separator, Fine Filter and Reheater, (if reheater isrequired) 200 Manifold with or without internal heater 300 Sander 400Air Filter Vacuum 500 Coating Metering and Dispensing Unit 600Water/Steam Generator with optional sediment and degassing water filtersdepending on water source, fixed gas content of the source water andwater temperature 700 Barrier Coating and Sealant 800 Carrying/InductionTube

Referring to FIG. 3, components 100-800 can be located and used atdifferent locations. The invention allows for an entire isolated pipingsystem to be cleaned in one single pass through run without having todismantle either the entire or multiple sections of the piping systemincluding no complete dismantling of the pipe and in-line pipeconnectors.

The piping system can include pipes having interior diameters of atleast approximately 12 mm with the piping including bends up toapproximately ninety degrees or more. The invention allows for an entirepiping section to have the interior surfaces of the pipes coated and ifpresent, leaks sealed in one single pass through run without having todismantle either the entire or multiple parts of the piping system.Coating of the internal wall surface of in-line fittings and valves aswell as exposed pipe ends located inside valves and inside in-linefitting/connectors can be accomplished in the same single passoperation. Each of the components will now be defined.

100 Air Generator

The air generator 100 can be outfitted to provide filtered and heatedcompressed air. The filtered and heated compressed air employed invarious quantities is used to dry the interior of the piping system,used as the propellant to drive the abrasive material used in cleaningof the piping system and is used as the propellant in the application ofthe barrier coating and the drying of the barrier coating once it hasbeen applied. The air generator 100 also provides compressed air used topropel ancillary air driven equipment. Air pressures and flow will bewidely dependent on the size and scope of the piping system to berestored. Pressurized air up to approximately 0.755 m³/s (1600 CFM) andup to approximately 1379 kPa (200PSI) can be used.

200 Air Distribution Manifold

A custom built air distribution manifold 200 can be one Manufactured By:Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif., USA,92821.

As part of the general air distribution system set up, the air manifold200 can be a pressure rated vessel designed to distribute the compressedair to at least 2 other points of connection, typically being theconnections to the piping system. Airflow from each connection at theair distribution manifold is controlled by the use of individual valves.

There are many novel parts and benefits to the air distribution manifold200. The portability of the air distribution manifold 200 allows foreasy to move and maneuver in tight working environments. The designprovides a stable base for the air distribution manifold 200 as well askeep the hose end connections off the floor or ground with sufficientclearance to permit the operator ease of access when having to make thehose end connections.

The air distribution manifolds 200 can be modular and can be used as 1unit or can be attached to other units and used as more than 1.Regulator adjustment can easily and quickly manage air capacitiesranging to approximately 0.755 m³/s (1600 CFM) and up to approximately1379 kPa (200PSI) can be used, and vary the operating airflows to eachof the other ancillary equipment associated with the invention. An airpressure regulator can be attached to the air distribution manifold 200which allows the operator to manage both regulated and unregulated airmanagement. An in-line electrical or gas type heater can be incorporatedinto or as part of the air distribution manifold 200 set up with atemperature regulator that will allow the operator access to heated airand temperature control.

300 Sander

A sander 300 that can be used with the invention can be one ManufacturedBy: Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif.92821.

The sander system 300 can provide easy loading and controlled dispensingof a wide variety of abrasive media. The sander can include operationalcontrols that allow the operator to easily control the amount of airpressure and control the quantity of the abrasive media to be dispersedin a single or multiple applications. The abrasive media can becontrolled in quantity and type and is introduced into a moving airsteam that is connected to a pipe or piping systems that are to beblasted clean by the abrasive media.

The abrasive media can be introduced by the sander 300 by beingconnected to and be located outside of the piping system depicted inFIG. 3. The novel application of the sander system 300 allows forcleaning small diameter pipes having internal diameters of at leastapproximately ±12 mm (½″) to ±50 mm (2″) and larger.

There are many novel parts and benefits to the use of the sander 300.The portability allows for easy to move and maneuver in tight workingenvironments. The sander 300 is able to accept a wide variety ofabrasive media in a wide variety of media size. Variable air pressurecontrols allows for management of air pressures up to approximately861.85 kPa (125 PSI.) A mixing valve adjustment allows for setting,controlling and dispensing a wide variety of abrasive media in limitedand controlled quantities, allowing the operator control over the amountof abrasive medium that can be introduced into the air stream in asingle or multiple applications. All operator controls and hoseconnections can be centralized for ease of operator use.

400 Air Filter Vacuum

An example of an air filter vacuum 400 used with the invention can beone Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street,Brea, Calif. 92821.

During the pipe profiling stage, the air filter vacuum 400 is the finalstage of the debris capturing and air filtration process. The air filtervacuum 400 filters the passing air of fine dust and debris from thepiping system.

During the drying stage the air filter vacuum 400 can be usedsimultaneously with the air supply 100 and aids in drawing air throughthe piping system. During the sanding or cleaning stage the air filtervacuum 400 can be used with the air supply 100, the air filter vacuum400 assists by drawing air through the piping system. The air filtervacuum 400 when used simultaneously with the air supply 100 creates apressure differential in the piping system which is used to reduce theeffects of friction loss within the pipe during the drying and sandingor cleaning stages as well as the coating stage. The air filter vacuum400 can also be used without the air supply 100 and can be used inconnection with air distribution manifold, where the air filter vacuum400 draws or blows heated air from the air distribution manifold 200permitting heated air to flow through the pipe assisting in variousdrying and heating stages while not relying on the use of the air supply100. The air filter vacuum 400 can also be used as an air blower.

500 Portable Thermoset Metering and Dispensing Unit

A metering and dispensing unit 500 used with the invention can be oneDistributed by: Sulzer MixPac, UK, Henson Way, Kettering, Northants,NN168PX, UK.

Metering can be conducted using prefilled cartridges which areidentified with a dispenser guide showing graduations of the amount ofmaterial which can be dispensed from the cartridge. Dispensing equipmentis capable of dispensing the Base and Activator components within ±5% ofthe specified mix ratio. The dispenser is fitted with a static typemixer having internal mixer elements.

Other than dispensing, no operator mixing is required with use of theprefilled ratio controlled cartridges/mixers. Cartridges are able todispense varying amounts of Base and Activator components depending onoperator selection ideally no less than approximately 25 ml mixed persingle application (shot size) and up to approximately 1.5 liters,mixed, (shot size) per single application.

The applicator device can include a dual cartridge pneumatic manualapplicator that is a hand-held, manually operated meter-mix dispenser.These dispensers provide a convenient, cost-effective method to applyproduct with minimal waste. The dispensers are compatible with multi mixratio products. Maximum inlet pressure of approximately 600 kPa (90PSI), maximum compressor air supply approximately 800 kPa (120PSI).Pressure adjustment, infinitely variable, sound level approximately 82dBA. Other types of metering and mixing units can be used.

600 Hot Water or Steam Generator

A portable hot water generator or steam generator can be comprised of aheating element, a storage tank, a thermostat, re-circulating pump,on-off valves, directional and pressure relief valves, water sedimentfilters and water degassing filter system. Off the shelf hot waterheaters can be obtained from Kamco Ltd, Hertfordshire, UK, AL2 2DD,filters can be obtained from GE Appliances, Louisville, Ky., USA 40225

700 Barrier Coating

A preferred barrier coating that can be used with the invention can beone manufactured by: CJH, Inc. 2211 Navy Drive, Stockton, Calif. 95206.The barrier coating product used in this process can be a 2-partthermoset resin with a base resin and a base-curing agent in which thecuring agent incorporates the use of amine adducts where the adducts arephenol free and plasticizer free.

Table 4 shows the formula and range formula for a preferred barriercoating.

TABLE 4 Percentage Percentage (actual) (actual) Range formula by Rawmaterial Wt. Vol. weight Resin epoxy 63% (67%) 40-80%  Curing Agent- 22%(28%) 5-45% Amine adduct, Adduct is phenol free and plasticizer free,Thixotrope 1.5%  (1%) 0-5%  Primary Coloring Pigment  9% (2%) 0-20%Fillers 4.5%  (2%) 0-60% Organic/inorganic

Examples of inorganic pigments can include but are not limited topigments selected from the group of titanium dioxide, carbon black, ironoxides, cadmium sulphides, zinc chromates, chromium oxides and azurite.

Examples of organic pigments can include but are not limited to pigmentsselected from the group of alizarin, anthoxanthin, arylide yellow, azocompound, bilin, bistre, bone char, caput mortuum, carmine, crimson,dragon's blood, gamboge, hansa yellow, indian yellow, indigo dye,naphthol red, ommochrome, phthalocanine blue BN, phthalocyanine green G,quinacridone, rose madder, rylene dye, sepia, tyrian purple.

Examples of inorganic fillers can include but are not limited to fillersselected from the group of aluminum silicate, calcium carbonate,magnesium silicate, ceramic zircon, metal powders, clay, silica,zirconium silicate, talc, mica, wollastonite, hydrated alumina.

Examples of inorganic fillers can include but are not limited to fillersselected from the group of both thermoset and thermoplastics which caninclude epoxy, polyurethane, acrylics, urea, melamine, bioplastic,polyamide, nylon.

Organic and inorganic fillers can be used alone or in combinations.

Test Conditions and Results

Leaching and analytical works were conducted at and verified by LGCLtd., Queens Road., Teddington, Middlesex, TW11 0LY, UK. Testing wasdone in September 2011.

Six lengths of 15 mm ID pipe were laid out and connected to the resinapplication system via flexible piping. Heated compressed air was thenapplied to the pipes to warm them to approximately 20° C. A two partresin was preheated to ≧approximately 35° C., mixed and inducted beforeinjecting the mixed coating material into the pipes. The mixed resin wasthen applied to the copper pipe using heated compressed air. Once theresin was visible in the clear plastic pipe connected to the end of thepipe it was considered coated and the procedure repeated for the nextpipe.

Once all the pipes had been coated, they were air cured by passingheated compressed air through at a temperature of approximately 20° C.for approximately 1 hour. Air temperatures were recorded using aninfrared thermometer at the pipe exit. Once the air curing stage wascompleted the pipes were interconnected using plastic piping and thenwater cured by passing heated water through at a temperature ofapproximately 55° C. for approximately 1 hour.

Once the curing stages were completed the pipes were visually inspectedfor cure and quality. A final 5 minute flush was then carried out usinga local mains water. The pipes were then taken to the laboratory toimmediately commence leaching tests. The entire process was thenrepeated using another set of six pipes.

Two different sets (SET 1 and SET 2) will now be described.

SET 1

Resin Mix temperature: 38° C.Pipe Temperature before addition of mixed resin: 21° C.Air cure time start: 09:32 01/09/2011Air cure time end: 10:32 01/09/2011Average pipe cure temperature: 19.4° C.Water cure time start: 10:45 01/09/2011Water cure time end: 11:45 01/09/2011Water cure temperature: 55.6° C.Flush time start: 11:55 01/09/2011Flush time end: 12:00 01/09/2011

SET 2

Resin mix temperature: 36° C.Pipe temperature before addition of mixed resin: 24.2° C.Air cure time start: 12:45 01/09/2011Air cure time end: 13:45 01/09/2011Average pipe cure temperature: 20.3° C.Water cure time start: 13:55 01/09/2011Water cure time end: 14:55 01/09/2011Water cure temperature: 55.0° C.Flush time start: 15:10 01/09/2011Flush time end: 15:15 01/09/2011

The preparation of three, 72 hour (T1, T2 and T3) leachates in bothnon-chlorinated and chlorinated test water was conducted in accordancewith BS EN 12873-2:2005). All leachates were analysed for TOC, BisphenolA, and Epichlorohydrin.

The preparation of non-chlorinated and chlorinated leachate and blanksamples and their analysis was conducted in accordance with therequirements of UK's Drinking Water Inspectorate (DWI) Regulation 31 forSpecific Deteminands tested according to BS EN 12873-2:2005.

TOC—Following blank subtraction the leachate samples had a TOC range of(less than)<0.10-0.36 mg/L. The blank samples had a TOC range of (lessthan)<0.10-0.10 mg/L.Bispehnol A—Following blank subtraction the leachate samples had aBisphenol A range of 0.3-0.5 μg/L. All blank samples had a Bisphenol Aconcentration of (less than)<0.2 μg/L.Epicholorhydrin—All leachate and blank samples had an Epichlorohydrinconcentration of (less than)<0.2 μg/L.

Samples were analysed using a GC-MS method which was validatedspecifically for this project. The estimated limit of detection is <0.2μg/L for Bisphenol A and Epichlorohydrin and a value at this is levelwould be equivalent to the 0.2 μg/ml solvent calibration standard.

Actual Tested SA:Vol dm⁻¹

Non-Chlorinated Samples: 31.90, Chlorinated Samples: 31.75 Note: 12 mmInterior Diameter Pipe: 33.33

Table 5 shows the TOC results for non-chlorinated samples andchlorinated samples.

TABLE 5 TOC Results TOC mg/L Leaching Period T = ±72 hrs Non-ChlorinatedSamples Chlorinated Samples T1 <0.10 0.36 T2 <0.10 0.29 T3 <0.10 0.24

Table 6 shows the Bisphenol A Results for non-chlorinated samples andchlorinated samples.

TABLE 6 Bisphenol A Results A μg/L Leaching Period T = ±72 hrsNon-Chlorinated Samples Chlorinated Samples T1 <0.2 0.5 T2 <0.2 0.4 T3<0.2 0.3

Table 7 shows the Epichlorohydrin Results for non-chlorinated samplesand chlorinated samples.

TABLE 7 Epichlorohydrin Results μg/L Leaching Period T = ±72 hrsNon-Chlorinated Samples Chlorinated Samples T1 <0.2 <0.2 T2 <0.2 <0.2 T3<0.2 <0.2

The preferred thermoset resin is mixed as a two-part product that isused in the invention. When mixed and applied, it forms a durablebarrier coating on pipe and fittings interior surfaces and othersubstrates. The barrier coating provides a barrier coating that protectsthose coated surfaces from the effects caused by the corrosiveactivities associated with the chemistry of water and other reactivematerials on the metal and other substrates and seal leaks in the pipeor fittings. Once applied and cured the preferred coating shall have apull test adhesion against the prepared substrate of at least 2758 kPa(400 PSI) or substrate failure.

The barrier coating and methods described can be applied to create aprotective barrier coating and leak sealant to pipes and fittings havingan internal diameter of at least approximately 12 mm (½″). The barriercoating can be applied around bends, intersections, elbows, t's, topipes having different diameters and make up.

The barrier coating can be applied to pipes in any position e.g.:vertical or horizontal, and can be applied as a protective coating tometal and plastic type pipes used in contact with potable water, as wellas fire sprinkler systems, natural gas systems, heating and coolingpipes. At least an average of approximately 100 micron (4 mils) coatinglayer can be formed on the interior walls of the pipes.

The barrier coating protects the existing interior walls and can alsostop leaks in existing pipes and fittings which have small openings andcracks, and the like, of up to approximately 125 mils in size. Althoughthe process of application described in this invention includesapplication of a specific thermoset resin, other types of thermosetresins such as but not limited to bis-maleimids (BMI), epoxy (epoxide),phenolic (PF), polyester (UP), polyimide, polyurethane (PUR) andsilicone can be used.

For example, other thermoset resins can be applied in the process, andcan vary depending upon viscosity, conditions for application includingtemperature, diameter of pipe, length of pipe, type of material pipecomprised of, application conditions, potable and non-potable watercarrying pipes, natural gas pipes, heating system pipes and based onother conditions and parameters of the piping system being cleaned,coated and leaks sealed by the invention.

Other thermoset type resins that can be used include but are not limitedto and can be one of many that can be obtained by suppliers such as butnot limited to: Dow Chemical, Hexion Chemicals, Aditya Birla Chemicalsand Air Products.

A preferred viscosity range of the mixed as-applied barrier coating usedin this process, before additional on-site fillers are introduced, whenmeasured at room temperature, wherein room temperature is described asbeing ±25° C. (±77° F.), is in the range of approximately 1.2 toapproximately 60 Pa-s (1,200 centipoise (cps) to approximately 60,000centipoise (cps)), and preferably in a narrow range of 5 to 35 Pa-s(5,000 cps to 35,000 cps).

The pot life, measured at room temperature wherein room temperature isdescribed as being ±25° C. (±77° F.), is preferably at leastapproximately 15 minutes. A preferred range of pot life would be fromapproximately 15 to approximately 45 minutes.

Additional fillers used in the process preferably can contain a mixtureof low and high aspect ratio particles, acicular shaped particles andother plate like particles.

Fillers preferably made of the same material that comprises the barriercoating can be used. Other materials may also be used include: glassflakes, glass fibers, epoxy fibers, mica, clay, silica, cork, plastics,acrylic, urea, melamine, thermoplastic, bio plastic, polyamide, nylon,thermosetting polymer or cellulose.

The amines used according to this invention can include aliphatic,cycloaliphatic or araliphatic amines like: 1,2-diaminoethane(ethylenediamine (EDA)); 1,2-propanediamine; 1,3-propanediamine;1,4-diaminobutane; 2,2-dimethyl-1,3-propanediamine (neopentanediamine);diethylaminopropylamine (DEAPA); 2-methyl-1,5-diaminopentane;1,3-diaminopentane; 2,2,4-Trimethyl-1,6-diaminohexane;2,4,4-Trimethyl-1,6-diaminohexane and mixtures thereof (TMD);1-amino-3-aminomethyl-3,5,5-trimethylcyclohexane;1,3-bis(aminomethyl)-cyclohexane; 1,2-bis(aminomethyl)cyclohexane;hexamethylenediamine (HMD); 1,2- and 1,4-Diaminocyclohexane (1,2-DACHand 1,4-DACH); bis(4-aminocyclohexyl)methane;bis(4-amino-3-methylcyclohexyl)methane; diethylenetriamine (DETA);4-azaheptane-1,7-diamine; 1,11-diamino-3,6,9-trioxundecane;1,8-diamino-3,6-dioxaoctane; 1,5-diamino-methyl-3-azapentane;1,10-diamino-4,7-dioxadecane; Bis(3-aminopropyl)amine; 1,13-diamino-4,7-10 trioxamidecane; 4-aminomethyl-1,8-diaminooctane;2-butyl-2-ethyl-1,5-diaminopentane; N,N-Bis-(3-aminopropyl)methylamine;triethylenetetramine (TETA); tetraethylenepentamine (TEPA);pentaethylenehexamine (PEHA); Bis(4-amino-3-methylcyclohexyl)methane;m-xylylenediamine (MXDA);5-(aminomethyl)bicyclo[[2.2.1]hept-2-yl]methylamine (NBDAnorbornanediamine); dimethyldipropylenetriamine;dimethylaminopropyl-aminopropylamine (DMAPAPA);3-aminomethyl-3,5,5-trimethylcyclohexylamine (or isophoronediamine(IPD)); diaminodicyclohexylmethane (PACM); mixed polycyclic amines(MPGA) (e.g. Ancamine 2168); dimethyldiaminodicyclohexylmethane (LarominC260); 2,2-Bis(4-aminocyclohexyl)propane; bisaminomethyl-dicyclopentadiene (tricyclodecyldiamine (TCD));imidazoline-group-containing polyaminoamides derived from aliphaticpolyethylene polyamines and dimerized or trimerized fatty acids andadducts thereof made from glycidyl compounds.

800 Carrying/Induction Tube

The mixed barrier coating can be placed into a carrying tube/inductiontube prior to injection into the piping system. A suitable inductiontube may be constructed of a food grade rated material such as a vinylflexible hose or tubing with connector ends enabling the induction tubeto be connected on one end to the incoming air supply and at the otherend (induction tube exit) to be connected either to the piping system orto an additional extension tube connected to the piping system.

Although the novel invention can be applied to all types of metal pipessuch as but not limited to lead pipes, brass pipes, copper pipes, steelpipes, galvanized pipes, and cast iron pipes, the invention can beapplied to pipes made of other materials such as but not limited toplastics, PVC (polyvinyl chloride), composite materials, polybutidylene,and the like. Additionally, small cracks and holes in plastic type andmetal pipes can also be fixed in place by the barrier coating leaksealant. Lead leaching from the coated lead substrate will be reduced toless than approximately 10 μg/L (10 ppb) preferably less than 1 μg/L (1ppb) when tested over a ±72 hour leaching period.

Although the preferred applications for the invention are described withsupply pipe and building piping systems, the invention can have otherapplications such as but not limited to include piping systems forswimming pools, underground pipes, in-slab piping systems, piping underdriveways, various liquid transmission lines, tubes contained in heatingand cooling units, tubing in radiators, radiant in floor heaters,chillers and heat exchange units, natural gas lines and the like.

While the invention has been described, disclosed, illustrated and shownin various terms of certain embodiments or modifications which it haspresumed in practice, the scope of the invention is not intended to be,nor should it be deemed to be, limited thereby and such othermodifications or embodiments as may be suggested by the teachings hereinare particularly reserved especially as they fall within the breadth andscope of the claims here appended.

1. A method for providing a protective barrier coating to interiorsurfaces of water pipes, comprising the steps of: providing waterservice pipes formed from metal having internal diameters of at leastapproximately 12 mm; coating interior surfaces of the water pipes with abarrier coating in a single pass; and curing the barrier coating toreturn the water pipes to service, wherein lead levels leaching intowater from the barrier-coated water pipes is less than 10 μg/L (10 ppb),wherein the water service pipes are cured and ready to be returned toservice in less than approximately 24 hours.
 2. The method of claim 1,further comprising the step of: providing a leak sealant barrier coatingas the barrier coating.
 3. The method of claim 1, wherein leachates,Bisphenol A and Epichlorohydrin leaching from the barrier coating to beless than approximately 1 μg/L (1 ppb).
 4. The method of claim 1,wherein the overall TOC levels leaching from the barrier coatingmeasured is less than approximately 2.5 mg/L (2.5 ppm).
 5. The method ofclaim 1, further comprising the step of: cleaning the inside surfaces ofthe pipes with a blasting media of particulates, the particulates beingselected from at least one of: calcium, silica, garnet, alumina,silicone, sodium, plastics, acrylic, urea, melamine, bio plastic,polyamide, nylon, or cellulose.
 6. The method of claim 1, furthercomprising the step of: substantially eliminating pin holing effects inthe coated interior pipe surfaces.
 7. The method of claim 1, furthercomprising the steps of: providing a 2-part thermoset coatingcomposition, comprising a base resin and a curing agent as the barriercoating, wherein the base-curing agent comprises a phenol-free andplasticizer-free amine adduct.
 8. The method of claim 7, furthercomprising the steps of: providing approximately 40 to approximately 80%resin epoxy as the base resin; and providing approximately 10 toapproximately 45% polyamine adduct as the curing agent.
 9. A method forproviding a protective barrier coating to the inside surfaces of metalpipes, comprising the steps of: providing metal-based pipes forsupplying water, the pipes being selected from one of lead, steel orcopper; cleaning inside surfaces of the pipes; coating the insidesurfaces of the pipes with a barrier leak sealant, wherein the insidesurfaces of the pipes are lined and sealed, in-place in a single-passthrough operation; and curing the coated barrier leak sealant insidesurfaces of the pipes, wherein heavy metal levels leaching from thecoated barrier leak sealant are less than approximately 10 μg/L (10ppb).
 10. The method of claim 9, further comprising the step of: curingthe coated barrier leak sealant to return the pipes to use.
 11. Themethod of claim 9, further comprising the step of: providing a thermosetresin coating as the barrier leak sealant.
 12. The method of claim 11,further comprising the step of: adding a phenol free and plasticizerfree amine adduct in the thermoset resin coating.
 13. The method ofclaim 9, further comprising the step of: providing the water pipes havean interior diameter of at least approximately 12 mm.
 14. The method ofclaim 11, wherein lead levels leaching into water from the coatedbarrier leak sealant inside surfaces of the water service pipes is lessthan 10 μg/L (10 ppb).
 15. The method of claim 11, wherein leachates,Bisphenol A and Epichlorohydrin leaching from the coated barrier leaksealant inside surfaces is less than approximately 1 μg/L (1 ppb). 16.The method of claim 11, wherein the overall TOC levels leaching from thecoated barrier leak sealant inside surfaces is less than approximately2.5 mg/L (2.5 ppm).
 17. The method of claim 11, further comprising:providing, as the barrier leak sealant, a two-part thermoset resincoating having hydrophobic qualities that permit the coating to be curedin place by an air curing period; and curing the coated barrier leaksealant with at least one of an air curing period, a water curingperiod, a steam curing period, or a combination thereof, without needfor a membrane barrier between the water or steam and the coatingmaterial.
 18. The method of claim 11, further comprising the step of:substantially eliminating pin-holing effects in the coated interior pipesurfaces.
 19. The method of claim 11, further comprising: providing a2-part thermoset coating composition, comprising a base resin and abase-curing agent as the leak sealant barrier coating, wherein thebase-curing agent comprises a phenol-free and plasticizer-free amineadducts.
 20. The method of claim 19, further comprising the steps of:providing approximately 40 to approximately 80% resin epoxy as the baseresin; and providing approximately 10 to approximately 45% polyamineadduct as the curing agent.